Contents 1. Why Clean? 2. What is Clean? 3. How to Clean 4. CIP Sequence 5. Detergents 6. Disinfectants 7. Hygienic Plant Design 8. Packaging 9. Chemical Safety
1. Why Clean?
Why Clean? Remove food for microbes Plant efficiency Discourage Pests Maintain beer quality flavour, clarity, head Keep Auditors happy! Safe working environment Remove Allergens Sell more beer!
Why Clean? Micro-organisms Microscopic, living organisms eg. Yeast (Brewing, Wild), Bacteria, Moulds Found throughout the planet, and responsible for recycling some elements Can double in number every 20 minutes in right conditions e.g. in 7 hours 1 bacterium can become 2.1 million bacteria
Why Clean? How do Micro-organisms get into Brewery? Water Ingredients Human hand washing / disinfection important Yeast from other breweries Air Pests Packaging Goods Returned containers
Why Clean? Effects of Yeast Contamination Adversely effect fermentation characteristics Off flavours from contaminants Continued re-contamination of pitching yeast Even acid washing won t remove Wild Yeast
Why Clean? Microbiological Off flavours, haze in beer Destroy beer / re-work Trade returns Customer confidence Sales reduction Company viability Job security
Process Heat exchange surfaces fouled Increased energy consumption Slower Cycle time Scale in mains reduces flow Fobbing Nucleation Why Clean? Particulates in Final Pack Effect on head retention head negatives
2. What is Clean?
What is Clean? Useful Definitions Soil - a substance found in the wrong place Detergent - a cleaning agent Disinfectant reduction of microbes to safe level Sterilant - misnomer for a chemical disinfectant Sanitisation Cleaning and disinfection of plant and equipment
What is Clean? Level of Cleanliness Different risks posed throughout the process Process Level of Cleanliness Brewhouse to Copper outlet Chemically Copper outlet to packaging Yeast propagation Microbiologically (Disinfected) Microbiologically (Sterilised)
What is Clean? Item being cleaned ie soil to be removed Brewhouse Very Heavy Soiling Caramelised Sugars Hop Materials Organic Soils Fermentation Heavy Soiling Yeast Ring Hop Extract Water Scale Beer Stone (Calcium Oxalate + Organics)
What is Clean? Maturation Light Soiling Beer Residues Water Scale Beer Stone Processing / Packaging Mixture! Beer Residues Water Scale Back from trade Dirty kegs ( beer residues, moulds, yeast,labels..) Dirty Casks Dirty Bottles still a few in UK
3. How to Clean
How to Clean Very dependent on the type of cleaning process and the plant design
Temperature Hot for Brewhouse & mains Can clean tanks cold Chemical Concentration Contact time How to Clean 5 4 3 2 1 0 0 0.5 1 1.5 2 2.5 3 3.5 4 The longer, the better chance of clean plant Can be shortened by eg increasing temperature and / or chemical concentration DE Relation Caustic content vs efficiency % w /v Caustic
How to Clean Mechanical effect achieved when the flow of liquid over the surface is fast enough Turbulent flow Mains >1.5 m/s
How to Clean Sprayballs High flowrate, low pressure Turbulent flow over vessel walls Good for vertical vessels Rotating Sprayballs Higher pressure, lower flowrate Good horizontal vessels Cleaning Machines Lower flow, higher pressure Great for Brewhouse
How to Clean Vessel cleaning Bursts far more effective Scavenge flow > delivery flow Avoid ponding Vacuum risk Hot to cold Caustic in Carbon Dioxide atmosphere
How to Clean
4. CIP Sequence
CIP Sequence Product Recovery Wort, beer, yeast is recovered from the pipework, Pre Rinse Detergent Intermediate Rinse Disinfection / Sterilisation Final Rinse
CIP Sequence Product Recovery Pre Rinse Removal of debris, this stage removes approx. 90% of debris from a surface. Sometimes heated but usually ambient. Detergent Intermediate Rinse Disinfection / Sterilisation Final Rinse
CIP Sequence Product Recovery Pre Rinse Detergent Removal of attached soil utilising a detergent, often caustic, can be acid or chlorinated caustic. This stage removes the remaining 10% of debris from a surface, often the stubborn / hard to remove debris. Intermediate Rinse Disinfection / Sterilisation Final Rinse
CIP Sequence Product Recovery Removal of the detergent and soil residues. Pre Rinse Detergent Intermediate Rinse Disinfection / Sterilisation Final Rinse
CIP Sequence Product Recovery Pre Rinse Detergent Disinfection either by temperature or chemical, brings the remaining micro loading on a surface to an acceptable level. Sterilisation usually by temperature kills all micro-organisms on a surface. Intermediate Rinse Disinfection / Sterilisation Final Rinse
CIP Sequence Product Recovery Pre Rinse Detergent Optional stage. Rinsing to remove chemical contaminants. Sometimes also used to heat or cool the plant in preparation for processing. Intermediate Rinse Disinfection / Sterilisation Final Rinse
5. Detergents
Detergents Alkaline / Acidic / Neutral Caustic breaks up organic soils Not used up Acids chemically react with inorganics Used up Oxidising compounds Hypo, PAA, Hydrogen Peroxide Break up soils Are consumed
Detergents - Caustic Lots formulations Additives to stop scale forming & to assist with cleaning water hardness EDTA required to stop Beer Stone 100% caustic is solid caustic 50% caustic highest liquid Freezing can be an issue: Strength (w/v) Freezing Point ( C) v/v to make 1% w/v 42.5 10 1.7 30.0 0 2.7 25.0-15 3.0
Detergents - Caustic Typical strengths used: Area % w/v Caustic C NB Brewhouse 3 70 to 85 Wort Cooler FV s 2 Either Carbon Dioxide Bright Beer 1 Ambient Carbon Dioxide Keg / cask washing 1 70 to 85 Aluminium Lots of factors determine % w/v caustic
Detergents - Caustic Water hardness must use correct blend at correct strength
Detergents - Caustic Carbon Dioxide neutralises Caustic Sodium Carbonate 10% of detergency power Soiling will drop out Vacuum created
Detergents - Acid Scale removal Beer Stone sulphuric acid based Water scale Nitric / phosphoric based Bright tank cleaning under pressure Don t have to remove CO 2 No need to purge out oxygen Measured v/v of product 1% v/v, ambient for bright beer 1 to 5% v/v for scale. Ambient to 50 C
Detergents - Chlorinated Chlorinated Caustic, blended or add hypo to caustic blend Very effective at removing organic material. But.
Detergents - Chlorinated Chlorinated Caustic, blended or add hypo to caustic blend Chlorine on Stainless Steel OK in Alkaline Conditions Too hot, or ph too low & chlorine gas given off Combines with water vapour to give Hydrochloric acid / Hypochlorous Acid Pitting corrosion (next slide) Don t use Chlorinated products at >50 C Don t use on plate heat exchangers Use Hydrogen Peroxide Chlorine plus beer = Chlorophenolic taint (TCP) Must never mix with acids > poisonous chlorine gas
Pitting Corrosion: Detergents - Chlorinated
6. Disinfectants
Disinfectants Can only effectively disinfect a CLEAN surface Some disinfectants break down, and are disabled by the presence of organic matter PAA, Chlorine, Chlorine Dioxide, Hydrogen Peroxide Must be the correct lethal concentration for the correct contact time Reducing micro-organisms to a safe level Stronger is not necessarily more effective and is more expensive Lethal concentration is enough, bugs can only die once!! Use for mains & vessels from wort cooling Use in soak baths Use in Open Plan Cleaning external hygiene Can be chemical and / or heat
Disinfectants PAA supplied as 5% & 15% products Use at 200 to 300 ppm for mains & vessels Use at 500 ppm for Soak baths 1.0 % v/v of 5% PAA -> 550 ppm PAA Breaks down into Acetic Acid, Water & Oxygen Don t have to rinse off High levels will stale beer Can get foaming PAA products Only use 15% in automated systems Chlorine Use in soak baths with care 150 to 200 ppm available chlorine % v/v depends on product
Disinfectants Avoid QUATS can be head negative Alcohols use neat for sample taps, hose ends etc Heat hot water & steam
7. Hygienic Plant Design
Hygienic Plant Design Materials Joints Shadows Dead legs Pumps; by-passes Sample points! Door rubbers; top of Anti-vacuum valves
Hygienic Plant Design Materials used 316L is the stainless steel most suitable Most resistance to chemicals Smooth surface Internal & external surfaces must be smooth No sharp corners in pipework or vessels Welds:
Shadows Hygienic Plant Design
Hygienic Plant Design Dead Legs A section of pipe where there is normally no flow and which is filled with stagnant process fluid No greater than 1.5 x pipe diameter in length
Door Rubbers: Hygienic Plant Design Anti-Vacuum valves:
8. Packaging
Packaging Cask Keg Bottle Can In all cases, we need the beer to contain a minimal number of spoilage organisms, and the packaging container to be as clean as possible, also containing the lowest possible number of microorganisms.
Packaging Cask It is very important to have a physically and microbiologically clean cask. Possible problems in casks, old / broken shives, foreign bodies (physical debris), scale, beer stone, flies etc The risks will be minimal if the cask is shiny clean metal, and free from any debris and scale. Wash casks on return to brewery don t leave until needed for filling Once washed seal Disinfect before filling Heavily formulated caustic containing EDTA works best. 1% w/v caustic at 70 to 85 C Disinfectant can be steam or PAA For hard to clean casks eg containing fly pupae cases. Soak with chlorinated caustic upto 50 C Aluminium casks can t use caustic. Use neutral product EDTA, phosphates etc Watch dirty gloves / hands on cask furniture
Keg (reusable) Similar requirements to cask Soiling should be far less Packaging Need to watch for carbonation of the caustic: often significant Measure it using eg dropper test kit If keg filing sequence doesn t involve steam blast over the spear after filling, spray spear with PAA or alcohol based product Keg (one trip) Spray spear with PAA or alcohol based product after filling
Packaging Bottle In UK usually glass non-returnable Rinse before filling ensure water is not infected Use low levels of PAA or chlorine dioxide - Treating rinse water Filler / capper hygiene Particularly important if no pasteurisation after fill Regular external cleans with foaming detergent & disinfectant Care if working inside filler / capper during packaging PAA or alcohol spray, alcohol wipes Environmental Chlorinated caustic foam
Packaging Can Very similar to non-return bottles
Packaging Foam Cleaning Range of products that when air is introduced produce a foam which slowly runs off surfaces far longer contact time than liquids Chemical energy and contact time are greatly increased, thereby reducing the amount of physical and thermal energy required Chlorinated caustics, caustics, PAA, Acids, etc available For optimal use apply with specialist foam equipment:
9. Chemical Safety
Chemical Safety - SDS Supplier has a legal requirement to supply a Safety Data Sheet to site either before or at the same time as the chemical arrives Electronic or hard copy Employer has a legal right to make the SDS available to the employee if they are being asked to work with that chemical Copies available in a file: if anyone needs medical attention, the SDS should be presented to the medical staff
Chemical Safety - COSHH Employer responsible for carrying out a COSHH Risk Assessment on each task that uses a chemical To minimise risk Appropriate PPE must be provided to employees when working with hazardous substances Responsibility of the employee to wear the PPE and follow the procedures
Talk to your supplier! Chemical Safety - Training
Any Questions? Please do not hesitate to contact us at: peter.thorman@holchem.co.uk 07736 487402 moyra.williams@holchem.co.uk 07974 189134 'we always do what we say we will do.'